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The Secret Life of S88 (S88 as Seen by Users) Jim Parshall Eli Lilly and Company.

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Presentation on theme: "The Secret Life of S88 (S88 as Seen by Users) Jim Parshall Eli Lilly and Company."— Presentation transcript:

1 The Secret Life of S88 (S88 as Seen by Users) Jim Parshall Eli Lilly and Company

2 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S882 Contents Interpreting S88 S88 Business Challenges The Future

3 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S883 Needs for Interpreting S88 n Standards serve countless companies in many different industries l Must be written to cover the broadest ground l Nature of standards prevents lengthy examples or interpretation details n S88.01 is not a compliance standard l It makes suggestions or provides examples l It does not list requirements

4 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S884 Reasons to Form SP88 n No universal model existed for batch control n Users had a very difficult time communicating their batch processing requirements n Engineers found it very hard to integrate solutions from different vendors n Engineers and users had a difficult time configuring batch control solutions

5 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S885 Spirit of S88 S88 works with all levels of automation nS88 isnt just a standard for software, equipment, or procedures nIts a way of thinking, a design philosophy nUnderstanding S88 will help you better design your processes and manufacture your products

6 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S886 How Does S88 Help? 1.Modularity allows for easier global replication and better return on investment 2.Isolates equipment from recipes 3.Design concepts make validation easier 4.S88-aware solutions help track product and process data 5.Gathering requirements from customers and conveying requirements to vendors is easier 6.Provides guidelines on how to recover from abnormal events

7 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S887 Improved Batch Process Metrics l Reduced batch cycle time l Increased production rate l Faster changeover time l More scheduled recipes l Reduced downtime l Faster process development time l Faster new product launches l Reduced raw material loss l Improved batch consistency l Better equipment utilization l Less time to add or modify recipes l Lower engineering cost l Lower data capture cost l Better data availability ThroughputCost

8 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S888 Successful Batch Control Defines These Elements n Instructions on how to make a product (recipes) n The physical tools needed to make a product (equipment entities) n Methods to link recipes to equipment entities (control activities)

9 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S889 A Recipe Make Toothpaste UnitProcedures Operations Phases Procedure Make Paste Prepare Tank Add Water Make GelSwirl Add Ingredients React Add FillersAdd NaF Phases are the workhorses. Other levels simply group, organize, and direct phases. Phases are the workhorses. Other levels simply group, organize, and direct phases.

10 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8810 An Example Process Cell Mix Discharge and Recirc Pressure Control Temperature Control Material Charging Material Selection M FT TT PT Pump Control Module Equipment Module Unit Process Cell FT

11 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8811 Interpretation of a Unit n Batching cannot occur without units; batching occurs in units n A unit runs a recipe to l Combine ingredients l Perform a reaction l Add value to your product or interim product n Dont narrow your definition of a unit to just a vessel l In-line mixer l Pasteurizer Control Module Equipment Module Unit Process Cell

12 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8812 What is a Unit? Mix making batch tank A Unit Not a Unit Reactor Pump Ingredient storage tank Washing machine Kitchen blender Refrigerator Dishwasher Pasteurizer

13 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8813 Discharge and Recirc Pressure Control Temperature Control Mix Material Charging Material Selection What is the Scope of a Unit? n Applying the S88 concept is much easier when equipment dedicated to a single unit is considered part of the unit n If a dedicated unit resource is not permanently associated with the unit, a lot of unneeded overhead is involved to use it M FT TT PT FT Pump

14 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8814 Equipment and Control Modules n Equipment modules group devices for performing one or more specific processing activities n Control modules connect software to the process through actuators and sensors with all elements treated as a single entity n Equipment modules run portions of a recipe; control modules do not Material Charging Equipment Module FT Material Selection Control Module Control Module Equipment Module Unit Process Cell

15 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8815 Physical Model is Collapsible n A control module does not have to be part of an equipment module to be part of a unit n A unit can own control modules directly n A process cell must contain at least one unit Control Module Equipment Module Unit Process Cell

16 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8816 Contents Interpreting S88 S88 Business Challenges The Future Interpreting S88 S88 Business Challenges

17 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8817 Packaged Systems n In bulk chemical operations, equipment entities (tanks, valves, pumps, etc.) are combined and integrated with control systems n S88 works well when end-user assembles stainless steel and integrates to form a working system n The application of S88 has been much more focused on these type of operations

18 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8818 Packaged Systems n Fill/finish-type operations found in the consumer products industries can benefit greatly from S88 n Equipment from these operations are typically purchased from various OEMs n Integration into a common S88 framework is difficult

19 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8819 What Do We Do? n Spec out equipment phases and have integrator or system OEM link equipment entities via recipes? n A two-tier S88-aware architecture n How about using S88.02 functions? l S88 software links recipes to equipment control at a level other than phase l S88 solution providers educate, assist, and influence OEMs to follow an S88 methodology

20 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8820 Contract Manufacturing n Interpretation of supply chain is changing n Contract manufacturing organizations (CMO) are growing and evolving l Used in food industry for years l Concept fairly new in pharmaceuticals n Product owners may evolve into R&D and marketing organizations l Manufacturing will evolve to third-parties l Sales already partly transforming to third-parties

21 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8821 Contract Manufacturing n Product owners will deal with general and site recipes n Product manufacturers will deal with master and control recipes n Properly transforming a general recipe into a master recipe will become even more critical

22 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8822 Contents Interpreting S88 S88 Business Challenges The Future S88 Business Challenges The Future

23 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8823 S88 Beyond Manufacturing n Theme park rides/attractions/shows l Instead of making a product according to some recipe, people are being entertained according to some sequence l Anyone visited Alien Encounter at Disneys Magic Kingdom? n Power generation l Thinking of power in batches does not seem to make sense, but state-based procedural control could be an asset to a power plant n Moving baggage at an airport

24 World Batch Forum 2000 / Atlantic CityApril 18, 2000The Secret Life of S8824 Final Thoughts n S88 being a standard with international influence is a big selling point n Make sure your vendors are aware of S88 n Dont underestimate the benefits of making your operators lives better n Make the process better n Dont trash the old system just yet n You may always have to sell S88 - even after projects are complete n An S88 solution is one element in a total system of manufacturing

25 Thank You


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